Building and Installing a Digital LED Billboard

August 11, 2016
mresources
Installing a digital billboard

Building and Installing a Digital LED Billboard

Designing, engineering, building and installing a digital LED billboard is no small task and at Media Resources we do it all from scratch from sizing and cutting the metal work to piecing the whole thing together, without the use of welding to all of the electical wiring and programming the LED components.  If that wasn’t enough we also make sure the entire unit is sealed tight and waterproofed, that the LED components are perfectly lined up and the whole unit is put together and tested right in our warehouse.  Then, we take it all apart and prep it for shipping, we load it safely onto a transport truck and we follow it to it’s new home and we install the whole thing.

What you, the consumer see’s when you drive by one of these huge LED billboards is all just the icing on the cake, below we will take you through the steps required to design, engineer, build and install a 14×48 foot long digital LED Billboard.

 

Custom extrusions are shipped to Media Resources from the supplier and stored until needed for a new build, at which time they are carefully inspected before production begins. Since Media Resources uses an extrusion-based construction we use this CNC saw to perform any end cuts and miters. An operator programs angles and dimensions and the machine is able to make 2 simultaneous cuts on both ends with incredible accuracy and speed. This greatly improves production throughput and consistency.

 

The frames are then laid out and assembled with a number of dimensional checks along the way. We use a number of jigs and clamps to ensure straightness and square-ness of the entire frame. This is critical as even the smallest mis-dimensions can affect the visual quality of an LED display.

The frames are then laid out and assembled with a number of dimensional checks along the way. We use a number of jigs and clamps to ensure straightness and square-ness of the entire frame. This is critical as even the smallest mis-dimensions can affect the visual quality of an LED display.

 

Building and installing a digital led billboard

The Media Resources VISIONiQ large frame system, colloquially referred to as “Big Iron”, requires absolutely no welding or drilling in its construction. This mitigates any potential quality defects due to the high craftsmanship requirement of welding or other human error. To create very long lengths, we use a combination of bolted plates and acrylic adhesive at the splice points, guaranteeing that these become actually the strongest parts of the section; this has been a known failure point in competitor’s systems.

 

Building and installing a digital led billboard

While our metalworking team is constructing the frame, our router team will be cutting faceplates and other auxiliary components using our CNC router. The faceplates will eventually hold the VISIONiQ modules. Because the faceplates are identical, the router team is able to build up a reserve of pieces so production is able to flow.

 

Building and installing a digital led billboard

Once the faceplates are cut and finished they are placed onto the box, aligned with a special jig and riveted into the extrusion frame. Rivet chases in the extrusion frame gather the rivets and position the faceplates automatically for a precise fit.

 

After the metalwork assembly is complete, a full inspection guarantees the frame is ready for population. The frame is then mounted to a moveable bracket system with castors that doubles as a shipping bracket. The population team then installs the LED modules, places power and control components, routes and connects cables/wiring, installs cabinet doors and hooks up the unit for test. Specialists then produce and install the networking and computing equipment into the door-mounted compartments.

Building and installing a digital led billboard

With all the assembly complete and subsystems tested, the entire board, sometimes produced in multiple sections, is fitment tested on our lifting gantries. Every board undergoes a high-power “burn-in” session of a minimum 48 hours to ensure that weaker components are “shaken out” before leaving the plant. Finally the board is inspected for visual quality and calibrated for colour accuracy.

 

Building and installing a digital led billboard

With testing complete and having been inspected my multiple levels of experts and management we disassemble the construction and slowly and carefully load the components onto the truck for shipping and delivery.

 

Building and installing a digital led billboard

Once on-site, the full size digital bulletin is lifted from the truck and quickly assembled on the ground before being lifted in a single piece. The Media Resources “Big Iron” system can be safely lifted with a two-point pick up with no spreader bar.

 

Building and installing a digital led billboard

Once lifted, the board is rested on its ledger brackets at the bottom, and a number of clamping features grip the steel I-beams to secure it in place. Finally, once electrical is hooked up and the onboard cellular modem makes its connection to the internet, the board is operational and generating revenue on the very same day.

 

 


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